Yarn carrier

ABSTRACT

A yarn carrier is provided in the form of a yarn winding tube having a yarn catch insert. The yarn winding tube includes a recess through its surface for receiving the insert. The insert includes a yarn catching slot having a major opening located at one end of the slot, a minor opening adjacent the major opening and positioned in a circumferential direction of the tube, and a first step extending substantially axially between the major opening and minor opening. A catching groove, having a portion with an axial width smaller than a diameter of the yarn, is also included. When the yarn carrier is rotated and the yarn is positioned along the yarn catching slot, the yarn drops into the major opening, slides along the first step and is directed into the catching groove for winding.

FIELD OF THE INVENTION

The present invention relates to a yarn carrier for winding yarnthereon. In particular, the yarn carrier includes a yarn catch insertpositioned within a recess formed within a hollow cylindrical tube.

BACKGROUND OF THE INVENTION

Yarn carriers, sometimes known as textile yarn cores, yarn winding tubesor yarn bobbins, are used in the textile industry to wind and support anelongated yarn. In order to make a yarn package, a moving yarn line isstrung up onto a rapidly rotating empty core. The moving yarn iscontacted with the rotating core and a catching, start-up or pick-upgroove is provided on the core to grip the yarn and start the windingoperating. The catching groove is normally located adjacent one end ofthe tube.

U.S. Pat. No. 5,927,637 to Gerharts shows a yarn carrier having atubular wall, which includes a yarn catching slot therein. The slotallows the bobbin to catch advancing yarn along a yarn catching tongue.The yarn catching tongue engages the yarn and slides the yarn into aclamping slot, which holds the yarn for winding.

US 2005/0077421 to Hernandez et al., shows in various embodiments a yarncarrier incorporating a yarn catch insert. The yarn carrier includes ahollow tube, having a hole in its surface to receive a yarn catchinsert. When positioned within the hole, the insert receives and catchesthe yarn in a groove formed by the insert. Once the yarn is caught inthe groove, the yarn is wound around the yarn carrier. The yarn catchinsert can be separated from the tube. The yarn catch insert can then becleaned and reinserted or replaced to reuse the tube for winding.

SUMMARY OF THE INVENTION

This present invention is a yarn carrier for winding yarn thereon. Theyarn carrier includes a hollow cylindrical tube having opposing ends.Adjacent one end of the tube is provided a recess formedcircumferentially along a portion of the tube wall. The recess may belocated proximal the end of the tube or may be spaced inwardly from thetube end. The recess extends radially through the tube wall.

The yarn carrier further includes a yarn catch insert positioned withinthe recess on the tube. The yarn catch insert includes a yarn catchingslot that extends in a circumferential direction of the tube. The slotincludes a major opening located at one end of the insert, a minoropening positioned adjacent the major opening and a first steppositioned between the major and minor openings. In one aspect of theinvention, the yarn catching slot may include a side flank, opposite thefirst step, which extends the length of the yarn catching slot. In afurther embodiment, the yarn catching slot may include a second step,opposite the first step. In a further embodiment, the yarn catch insertmay comprise first and second members that are coupled together to formthe yarn catching slot.

A catching groove is provided having a width that is smaller than thediameter of the yarn to be wound on the tube. The catching groove ispositioned adjacent the minor opening of the insert. The groovegenerally extends in a circumferential direction, opposite the majoropening. The catching groove may be formed as part of the insert orwithin the tube wall.

Upon rotation of the yarn carrier, the yarn is positioned substantiallytangent to the tube wall and in a generally circumferential directionalong the yarn catching slot. The yarn drops into the major opening andslides along the first step into the minor opening. After entering theminor opening, the yarn is engaged by the catching groove, which holdsthe yarn end and winding is initiated.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, the drawings show formsof the invention that are presently preferred. However, it should beunderstood that the invention is not limited to the precise argumentsand instrumentalities shown in the drawings.

FIG. 1 is a partial exploded perspective view of a yarn carrier having ayarn winding tube and yarn catch insert.

FIG. 2 is a partial side elevation of the yarn carrier of FIG. 1 withthe insert positioned within a recess in the tube.

FIG. 3 is a partial side elevation of another embodiment of a yarn catchinsert within a yarn winding tube.

FIG. 4 is a partial side elevation of a further embodiment of a yarncatch insert within a yarn winding tube.

FIG. 5 is perspective view of another embodiment of a yarn catch insert.

FIG. 6 is a partial perspective view of a yarn carrier showing the yarncatch insert of FIG. 5 positioned within a recess in a yarn windingtube.

FIG. 7 is a perspective view of a further embodiment of a yarn catchinsert.

FIG. 8 is a partial perspective view of a yarn carrier showing the yarncatch insert of FIG. 7 positioned within a recess in a yarn windingtube.

FIG. 9 is a partial exploded perspective view of a further embodiment ofa yarn carrier having a yarn winding tube and a yarn catch insertpositioned in a recess proximal the end of the tube.

FIG. 10 is a partial side elevation of the embodiment of a yarn carrierof FIG. 9.

FIG. 11 is a partial side elevation of a further embodiment of a yarncatch insert positioned within the tube of FIG. 9.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, wherein like numerals indicate likeelements, there is shown various exemplary embodiments of a yarn carrieraccording to the present invention. The yarn carrier is contemplated tobe used in the textile industry to wind yarn thereon.

FIG. 1 shows the formation of a yarn carrier 110 as contemplated by oneembodiment of the present invention. The yarn carrier 110 includes ahollow cylindrical winding tube 112 having a longitudinal axis andextending between a first end 114 and a second end (not shown), at theopposite end of the tube 112. The tube 112 includes a substantiallycylindrical outer surface 116 and inner surface 118, with the tube wallformed therebetween. A recess 120 is formed adjacent the first end 114of the tube 112 and extends circumferentially around a portion of thetube wall. The recess 120 is spaced axially inward from the tube end114. The recess 120 extends radially from the inner surface 118 to theouter surface 116 of the tube 112, forming a hole in the tube wall. Asillustrated in FIG. 1, a yarn catch insert 122 is inserted into therecess 120 and has a form that generally conforms to the shape of therecess 120. The tube 112 and yarn catch insert 122 may be made out ofany suitable materials known in the industry for forming yarn carriers,including, but not limited to, plastic, metal, paper or cardboard.

Referring now to FIG. 2, the yarn carrier 110 of FIG. 1 is shown withthe yarn catch insert 122 positioned in the recess 120 in the tube 112.The yarn catch insert 122 includes a yarn catching slot 124 that extendsin the circumferential direction of the tube 112. The yarn catching slot124 includes a major opening 126 located at one end and a relativelysmaller, minor opening 128 positioned adjacent the major opening 126. Afirst step 130 is formed between the major opening 126 and minor opening128. The first step 130 extends in the axial direction of the tube 112.The step 130 includes an outer surface 132 substantially flush with theouter surface 116 of the insert 122 and the tube 112. The yarn carrier110 further includes a catching groove 134 having an axial width that issmaller than a diameter of a yarn 136. The catching groove 134 ispositioned adjacent the minor opening 128 and extends in acircumferential direction from the end of the minor opening 128 oppositethe major opening 126. The catching groove may be tapered or have atapered portion.

In operation, the yarn carrier 110 rotates about its longitudinal axisas shown by rotation arrow 138. The yarn 136 is positioned tangentiallywith respect to the tube wall and generally in a circumferentialdirection. The yarn 136 is moved to a position along the yarn catchingslot 124. The yarn 136 drops into the major opening 126, slides alongthe first step 130 and into the minor opening 128, and then is engagedby the catching groove 134. The catching groove 134 grabs the yarn 136and initiates winding of the yarn 136 around the tube 112.

The yarn catching slot 124 shown in FIG. 2 includes a side flank 142opposite the first step 130. The side flank 142 extends the length ofthe yarn catching slot 124. The side flank 142 serves to direct the yarn136 toward the catching groove 134.

Referring now to FIG. 3, a yarn carrier 310 is shown having an alternateembodiment of a yarn catching insert 322 positioned within a windingtube 312. The insert 322 includes a yarn catching slot 324 that extendsin a circumferential direction of the tube 312. The slot 324 includes amajor opening 326 located at one end of the slot 324 and a minor opening328 positioned adjacent a major opening 326. A first step 330 is formedbetween the major opening 326 and the minor opening 328. The first step330 extends in the axial direction of the tube 312.

A second step 346 is provided in a side flank 348, opposite the firststep 330. The second step 346 generally extends in the axial directionof the tube 312 and includes an outer surface 332 formed substantiallyflush with the outer surface of the insert 322 and an outer surface 316of the tube 312. Upon rotation of the tube 312 in a direction 338, ayarn 336 will drop into the major opening 326. The yarn 336 will thenslide along either the first step 330 or the second step 346 and intothe minor opening 328. After entering the minor opening 328, the yarn336 is directed into the catching groove 334 and engaged thereby,causing winding of the yarn 336 on the tube 312.

Referring now to FIG. 4, a yarn carrier 410 is shown having a furtherembodiment of a yarn catching insert 422 formed within a recess 420 in awall 416 of a tube 412. The insert 422 is spaced axially from one end414 of a tube 412. The insert 422 includes a yarn catching slot 424 thatgenerally extends in the circumferential direction of the tube 412. Theslot 424 includes a major opening 426 located at one end of the slot 424and a minor opening 428 positioned adjacent a major opening 426. A firststep 430 is formed within the minor opening 428 and extends into acatching groove 434. The first step 430 extends substantially in theaxial direction of the tube 412. The catching groove 434 has an axialwidth that is smaller than a diameter of the yarn 436. The insert 422further includes an outer surface 432, which is substantially flush withthe outer surface 416 of the tube 412. As shown, the yarn 436 isslightly angled with respect to the axis of the tube 412, which isrotated in the direction of arrow 438. The yarn 436 drops into the majoropening 426 and is engaged by the first step 430, which is angled. Theyarn 436 then slides along the first step 430 into the catching groove434 and is engaged by the tapered end. The yarn passes under the step430 and into the minor opening 428.

The catching groove 434 may include internal sidewalls inclined withrespect to each other so as to diverge while moving inwardly from theoutside surface 432 toward the inner surface (not shown). The angle ofthe step 430 with respect to the circumferential direction of the tubeor with respect to the catching groove 434 may be varied as desired toaccommodate different yarn types.

Referring now to FIG. 5, a further embodiment of a yarn catch insert 522is shown. The yarn catch insert 522 includes a first member 554 having afirst end 556 and a second end 558 opposite the first end 556. The firstmember 554 also includes an inner surface 560. A second member 562 isprovided having a first end 564, a second end 566 and an inner surface568. The inner surface 568 of the second member 562 faces the innersurface 560 of the first member 554, when the first member 554 and thesecond member 562 are positioned in a recess 520 (as shown in FIG. 6),and define the catching slot 524.

The second end 558 of the first member 554 is coupled to the second end566 of the second member 562 by a coupling tab 570. Although theembodiment shown in FIGS. 5 and 6 is coupled, the first member 554 andsecond member 562 of the insert 522 may also be integrally formed or anassembly of separate members.

Referring particularly to FIG. 6, a yarn carrier 510 is shown having theinsert 522 positioned within a recess 520 spaced from an edge 514 of atube 512. The yarn catching slot 524 is positioned in thecircumferential direction of the tube 512. The slot 524 includes a majoropening 526 located at one end and a minor opening 528 positionedadjacent the major opening 526. A first step 530 is formed between themajor opening 526 and the minor opening 528. The first step 530 extendssubstantially in the axial direction of the tube 512. A catching groove534 is provided having at least a portion with an axially width that issmaller than a diameter of a yarn 536. The catching groove 534 ispositioned adjacent the minor opening 528 and extends in acircumferential direction of the tube 512, opposite the major opening526. As illustrated, the groove 534 is formed on the surface of the tube512 and communicates through the ends 566 and 564 of the first andsecond members 554 and 562.

When the tube 512 is rotated in a direction 538, the yarn 536 is movedinto the slot 524 via the major opening 526 and slides across the firststep 530 into the minor opening 528. The yarn 536 is directed by theminor opening 528 into the catching groove 534 located at the end of theminor opening 528 and formed within the tube 512.

Referring now to FIG. 7, a further embodiment of a yarn catch insert 722is shown. Much like the insert 522 of FIG. 5, the yarn catch insert 722includes a first member 754 having a first end 756 and a second end 758opposite the first end 756. The first member 754 also includes an innersurface 760. A second member 762 is provided having a first end 764, asecond end 766 and an inner surface 768. The first member 754 and thesecond member 762 may be coupled using a coupling tab 770. The innersurface 768 of the second member 762 faces the inner surface 760 of thefirst member 754 when the first member 764 and the second member 762 arepositioned within a recess 720 (as shown in FIG. 8) and defines thecatching slot 524.

Referring now to FIG. 8, a yarn carrier 710 is shown having the insert722 positioned within a recess 720 in the wall of the tube 712 andspaced from one end 714. The insert 722 includes a yarn catching slot724 which is positioned to extend in the circumferential direction ofthe tube 712. The slot 724 includes a major opening 726 located at oneend of the slot 724 and a minor opening 728 positioned adjacent themajor opening 726. A first step 730 is formed between the major opening726 and minor opening 728. The first step 730 extends substantially inthe axial direction of the tube 712. As discussed above, a second step(not shown) may also be provided, opposite the first step, or adjacentthe catching groove.

The insert 722 includes an outer surface 734 which is formed so as to beflush with the outer surface 716 of the tube 712. The insert 722 furtherincludes a catching groove 734 having an axial width that is smallerthan the diameter of a yarn 736. The catching groove 734 is positionedadjacent the first step 730 between the minor opening 728 and the majoropening 726. A second catching groove 772 is formed within the tube 712adjacent the minor opening 728 extending in a circumferential directionfrom the minor opening 728 opposite the major opening 726. The secondcatching groove 772 is provided having an axial width that is smallerthan the yarn 736. The insert 722 includes a top surface 732 flush withthe outer surface 716 of the tube 712.

When the tube 712 rotates in the direction of arrow 738, the yarn 736falls inside the major opening 726. The yarn 736 can then take either oftwo directions. First, the yarn 736 can fall within the major opening726 and engage the first step 730. The yarn 736 then slides along thefirst step 730 into the catching groove 734. Alternatively, the yarn 736can move along the length of the yarn catch insert 722 and through thetop end 774 of the slot 724 into the second catching groove 772. Thus,depending on the position of the yarn 736 when it enters the yarncatching slot 724, the yarn 736 could either be engaged by the firstcatching groove 734 or the second catching groove 772 for winding.

Referring now to FIG. 9, a further embodiment of the yarn carrier 910 isprovided. The yarn carrier 910 includes a tube 912 having asubstantially cylindrical outer surface 916 and inner surface 918 withthe tube wall formed therebetween. As shown in FIG. 9, a yarn catchinsert 922 is positioned adjacent a recess 920 and has a form thatgenerally fits within the recess 920. A recess 920, if formed within thetube 912, extends to an edge 944 of the tube 912 at a first end 914 ofthe tube 912.

Referring now to FIG. 10, the yarn carrier 910 is shown with the insert922 positioned within the recess 920. The insert 922 includes a yarncatching slot 924 extending in the circumferential direction of the tube912. The slot 924 includes a major opening 926 located at one end of theslot 924 and a minor opening 928 positioned adjacent the major opening926. A first step 930 is formed within the minor opening 928 extendingsubstantially axially in the direction of the tube 912. The first step930 includes an outer surface 932 flush with the outer surface 916 ofthe tube 912. The insert 922 further includes a catching groove 934having an axial width smaller than a diameter of a yarn 936. Thecatching groove 934 is positioned adjacent a minor opening 928 andextends in a circumferential direction away from the minor opening 928opposite the major opening 926. When the tube 912 is moved in anintended direction of rotation 938, the yarn 936 will drop into the slot924 at the major opening 926. The yarn then slides along the first step930 within the minor opening 928 and moves into the catching groove 934.The catching groove 934 secures the yarn 936 for winding.

Referring now to FIG. 11, a further embodiment of a yarn carrier 1110 isprovided having a yarn catch insert 1122 positioned within a recess 1120of a tube 1112. The recess 1120 is formed within the tube 1112 extendingto an edge 1144 of the tube 1112 at a first end 1114. The insert 1122includes a yarn catching slot 1124 that extends in the circumferentialdirection of the tube 1112. The slot 1124 includes a major opening 1126located at one end of the slot 1124 and a minor opening 1128 positionedadjacent the major opening 1126. A first step 1130 is formed within theminor opening 1128 extending substantially in the axial direction of thetube 1112. The first step 1130 further includes an outer surface 1132flush with the outer surface 1116 of the tube 1112. The insert 1122includes a catching groove 1134 having an axial width that is smallerthan a diameter of a yarn 1136. The catching groove 1134 is positionedadjacent the minor opening 1128 and extends in a circumferentialdirection away from the minor opening 1128 opposite the major opening1126.

When the tube 1112 is moved in an intended direction of rotation 1138,the yarn 1136 falls into the yarn catching slot 1124 at the majoropening 1126 and engages the first step 1130 within the minor opening1128. The yarn 1136 then slides along the first step 1130 in the minoropening 1128 and is engaged by the catching groove 1134. The catchinggroove 1134 secures the yarn 1136 for winding.

As shown in the yarn catch insert 922 embodiment of FIG. 10, a yarn 936engaged in a catching groove 934 can remain above the outer surface 916of the tube. Alternatively, as shown in the yarn catch insert 1122 ofFIG. 11, a yarn 1136 engaged by the catching groove 1134 can bepositioned both under the outer surface 1116 of the tube 1112 on one end(near the inner surface 918 of the tube 912) and above the outer surface1116 of the tube 1112 on another end. Positioning the recess along anedge of the tube can also facilitate manufacturing and enlarging thearea that the yarn can travel to drop into the major opening.

For all embodiments, the yarn catch insert facilitates removal from thetube and cleaning of the catching groove. Thus, the tube of the yarncarrier can be reused or the operator may replace the yarn catch insert,if needed. Moreover, the universal shape of the recess allows for asingle tube to be used multiple times and with multiple yarn catchingslot formations. Thus, the denier of a yarn to be wound can be changedwith the winding tube still being useful.

Although the invention has been described and illustrated with respectto the exemplary embodiments thereof, it should be understood by thoseskilled in the art that the foregoing and various other changes,omissions and additions may be made therein and thereto, without partingfrom the spirit and scope of the present invention.

1. A yarn carrier for winding yarn thereon, comprising: a hollowcylindrical tube having a longitudinal axis extending lengthwise betweena first end and second end; a tube wall defined by a substantiallycylindrical outer and inner surfaces, and a recess formed adjacent thefirst end of the tube and extending in a circumferential direction ofthe tube, the recess extending radially throughout the wall; and a yarncatch insert positioned within the recess, the insert comprising a yarncatching slot formed within the yarn catch insert and extending in acircumferential direction of the tube, the yarn catching slot comprisinga major opening located at one end of the slot, a minor openingpositioned adjacent the major opening and aligned in a circumferentialdirection, a first step positioned between the major opening and theminor opening and substantially axially, the first step comprising anouter surface form flush with the outer surface of the insert and flushwith the outer surface of the tube; and a catching groove having anaxial width smaller than a diameter of a yarn, the catching grooveextending in a circumferential direction opposite the major opening,wherein upon rotation of the yarn carrier about the longitudinal axis,the yarn positioned circumferentially along the yarn catching slot dropsinto the major opening, slides along the step and is directed into thecatching groove.
 2. The yarn carrier of claim 1, wherein the catchinggroove is positioned adjacent the minor opening.
 3. The yarn carrier ofclaim 1, wherein the catching groove is positioned in the tube wall. 4.The yarn carrier of claim 1, wherein the yarn slides into the minoropening.
 5. The yarn carrier of claim 4, wherein the catching groovecomprises side walls having a substantial axial component inclined withrespect to each other so as to form an acute angle when viewed in plan.6. The yarn carrier of claim 4, wherein the yarn catch insert furthercomprises a first member comprising a first end, a second end oppositethe first end, an inner surface, and a second member having a first end,a second end, and an inner surface facing the inner surface of the firstmember when the first and second members are positioned in the recess;wherein the second end of the first member is coupled to the second endof the second member.
 7. The yarn carrier of claim 4 further comprisinga second catching groove located at a top end of the yarn catching slot.8. The yarn carrier of claim 4, wherein the recess extends to an edge ofthe tube.
 9. The yarn carrier of claim 1, wherein the yarn catching slotcomprises a side flank opposite the first step extending thecircumferential length of the yarn catching slot parallel to an edge ofthe tube.
 10. The yarn carrier of claim 1, wherein the yarn catchingslot further comprises: a second step opposite the first step extendingaxially, the second step comprising an outer surface flush with theouter surface of the tube, wherein upon rotation of the yarn carrierabout the longitudinal axis, the yarn positioned circumferentially alongthe yarn catching slot will drop into the major opening, slide alongeither the first step or the second step into the minor opening, andthen be engaged by the catching groove.
 11. The yarn carrier of claim 1,wherein the yarn is engaged by the catching groove in a substantiallyperpendicular direction.
 12. The yarn carrier of claim 11, wherein oneof the side walls of the catching groove forms a continuation of thefirst step.
 13. The yarn carrier of claim 1, wherein the yarn catchinsert further comprises: a first member comprising a first end, asecond end opposite the first end, an inner surface, and a second memberhaving a first end, a second end, and an inner surface facing the innersurface of the first member when the first and second members arepositioned in the recess; wherein the second end of the first member iscoupled to the second end of the second member.
 14. The yarn carrier ofclaim 1, wherein the hollow cylindrical tube is plastic, paper, metal,or cardboard.
 15. The yarn carrier of claim 1, wherein the yarn catchinsert is plastic, paper, metal, or cardboard.
 16. A yarn carrier forwinding yarn thereon, comprising: a hollow cylindrical tubular wallhaving a longitudinal axis extending lengthwise between first and secondopposite ends thereof, and a recess formed in the first end of the wallextending radially though the wall and circumferentially in a directionof rotation of the yarn carrier; and a yarn catch insert positionedwithin the recess, the insert comprising a yarn catching slot formedwithin the yarn catch insert extending circumferentially in a directionof rotation of the yarn carrier, the yarn catching slot comprising amajor opening located at one end of the slot, a minor opening positionedadjacent the major opening extending circumferentially in a directionaway from the direction of rotation of the yarn carrier, a first stepbetween the major opening and the minor opening extending axially andfacing the direction of rotation of the yarn carrier; and a catchinggroove having an axial width smaller than a diameter of a yarn, thecatching groove positioned adjacent the minor opening and extendingcircumferentially in a direction away from the direction of rotation ofthe yarn carrier; wherein upon rotation of the yarn carrier about thelongitudinal axis, the yarn positioned circumferentially along the yarncatching slot will drop into the major opening, slide along the stepinto the minor opening, and then be engaged by the catching groove. 17.The yarn carrier of claim 16, wherein a top surface of the step is flushwith an outside surface of the tubular wall.